Integrated Pump Controller in Sensor Electronics
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Solution Overview
Problem
Existing pump systems with programmable logic controllers (PLCs) are complex and costly, requiring external electronics for motor control, which increases system complexity and costs.
Innovation Solution
Integration of a pump controller into sensor electronics within the motor housing, eliminating the need for a separate PLC or external electronics package by using sensor electronics to command the motor controller directly, thereby simplifying the system and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PLC or external electronics housing is used for motor control, then reliable pump system control is achieved, but system complexity and costs increase
Solution Approach 1:
The pump controller is integrated directly into the sensor electronics housing, combining the functions of sensing, control, and motor regulation into a single unified unit. This eliminates the need for separate PLCs or external electronics housings, thereby reducing system complexity while maintaining control reliability through the unified architecture.
Solution Approach 2:
The sensor electronics housing performs multiple functions: it houses the sensor for detecting pump parameters, contains the pump controller for processing sensor data, and provides motor control outputs for regulating the drive motor. This multi-functional integration reduces the number of separate components needed in the system.
2Reliability
If a PLC or external electronics housing is used for motor control, then reliable pump system control is achieved, but system costs increase
Solution Approach 1:
The pump controller is integrated directly into the sensor electronics housing, combining the functions of sensing, control, and motor regulation into a single unified unit. This eliminates the need for separate PLCs or external electronics housings, thereby reducing system complexity while maintaining control reliability through the unified architecture.
Solution Approach 2:
The sensor electronics housing performs multiple functions: it houses the sensor for detecting pump parameters, contains the pump controller for processing sensor data, and provides motor control outputs for regulating the drive motor. This multi-functional integration reduces the number of separate components needed in the system.
3Device complexity
If sensor electronics are integrated into the sensor, then system complexity is reduced, but control functionality must be maintained
Solution Approach 1:
The sensor electronics housing performs multiple functions: it houses the sensor for detecting pump parameters, contains the pump controller for processing sensor data, and provides motor control outputs for regulating the drive motor. This multi-functional integration reduces the number of separate components needed in the system.
Solution Approach 2:
The sensor electronics housing serves as an intermediary unit that receives data from the sensor, processes it through the integrated pump controller, and generates control signals for the motor controller. This intermediary structure maintains clear functional separation while achieving physical integration, preserving control versatility.
Data Source
Figure 1
Figure 2a~2e
Figure 3
AI summary
The present disclosure relates to a pump system (1) with a first (3) of at least one pump unit (3, 5) for pumping a fluid (11), wherein the first pump unit (3) comprises a pump, an electric drive motor and a motor control, a pump control for commanding the motor control, and a sensor (7) with a sensor housing (27) and sensor electronics (28) located in the sensor housing (27) for detecting at least one parameter of the fluid (11) in the pump or in a pipe fluid-connected to the pump, wherein the pump control is integrated into the sensor electronics (28).